The Good Tech Companies - From Failure Data to Futureproof Design: The Engineer Turning Battery Risks into Predictive Safety

Episode Date: December 30, 2025

This story was originally published on HackerNoon at: https://hackernoon.com/from-failure-data-to-futureproof-design-the-engineer-turning-battery-risks-into-predictive-safety. How Aravind Reddy Boozula turns battery failure data into predictive safety using physics-informed AI to prevent breakdowns. Check more stories related to science at: https://hackernoon.com/c/science. You can also check exclusive content about #predictive-maintenance, #energy-systems-engineering, #battery-safety, #battery-management-systems, #grid-resilience, #industrial-energy-storage, #lithium-ion-batteries, #good-company, and more. This story was written by: @jonstojanjournalist. Learn more about this writer by checking @jonstojanjournalist's about page, and for more stories, please visit hackernoon.com. Engineer Aravind Reddy Boozula reframes battery failure as intelligence. By combining physics-based models with machine learning, he designs battery systems that detect risk early, adapt to real-world conditions, cut downtime by up to 30%, and reduce thermal runaway incidents. His work turns failure data into predictive safety baked directly into modern energy infrastructure.

This audio is presented by Hacker Noon, where anyone can learn anything about any technology. From failure data to future-proof design, the engineer turning battery risks into predictive safety by John Stoy and journalist. When it comes to advanced energy systems, the real progress isn't about cranking out more power. It's about getting smarter at stopping things from going wrong in the first place. Every blown fuse, every hotspot, every weird voltage drop is a story behind it, choices made, materials pushed to their limits, and physics doing what physics does. Most engineers see failure as a headache. Not Arvind Reddy Boozula. He sees Eda's the best kind of data thanks to his past and current experience in energy systems, including gas, diesel, and batteries,

for perspective. People call him the systems architect of safety, and honestly, the name fits. He doesn't just analyze battery systems. He reimagines them so they can almost think for themselves. Some engineers double up on backups when things go wrong. He adds intelligence, so batteries sense trouble before it turns into failure. His goal? Not just tougher batteries, but smarter ones. Back when he was starting out, Arv and Reddy Buzula saw something others missed. Energy systems don't fall apart because of sloppy design. They break down because their designs ignore the messy, changing reality they live in. Moss models treat safety like a box to check, he once said. But safety-outes,

actually shifts all the time, it depends on how people use the system, where it sits, and what's happened to it. That idea drove him to mix physics-based modeling with machine learning as part of the battery management system, BMS. Recent advances in that hybrid field back him up. Physics-informed machine learning has been shown to cut structural failure and battery degradation due to vibrations and enhance the life of battery systems by over 7%. He has built tools that turn live battery data into early warning signs, catching trouble well before human operators could in sodium ion batteries. His signature project is a total redesign of large industrial battery modules. Traditional systems used to wait for alarms to go off after something went on.

Buzula suggests a health inference layer, a kind of digital brain that's its between the sensors and the control system, learning what slow structural failure and cell degradation look like. Instead of merely tracking temperatures or voltage, it correlates that data with local local weather, workload, and material fatigue. The result. A predictive safety model that reduced unplanned downtime by up to 30% in test grids. That same approach revolutionized resilience in severe weather. While most engineers add redundancy, Buzula coded adaptability straight into the architecture. He dug into over-grid failures from extreme weather as suggested in a recently published article on lithium-ion batteries that goes by the name, an overview of the impact of

vibrations on Li-ion battery performance, degradation, battery thermal management system and key focus areas, tracking exactly how batteries wear down under pressure. Once he saw the patterns, he put them to use. Now, when the grid starts acting up, his tech steps in, locking down risky areas and keeping the most important systems running. This smart, responsive setup fits right in with the latest IEE the 1st of February 2030 standards for resilient battery management. He didn't just keep these breakthroughs to himself either. Bozula teamed up with safety boards and manufacturers, turning his predictive safety ideas into real certification standards. Thanks to this work, say J-292929 and J-2,380, Vibration and Shock Subcommittee Lead, are getting updated to make

energy storage safer. And it's making a difference, thermal runaway incidents in big lithium-ion battery systems dropped almost 25 percent from 2021 to 2024. DNV-Based. Battery Performance Report, 24, people who work with him say he brings together technical precision and creative foresight. As one colleague put it, he doesn't just design components, he designs confidence. That sums it up. Bozula transforms failure data into foresight, turning what once were accidents into algorithms of prevention. Now that electrification touches everything from vehicles to factories, the risks are greater and the margins thinner. Batteries are no longer sealed black boxes, their nodes in a living, self-aware network. In that fast-changing world,

Arvind Ready-Buzula's work shows that progress isn't about stopping failure cold. It's about learning from every misstep and using that knowledge to make sure failure barely stands a chance next time. For him, safety isn't just about avoidance, its intelligence built in. Thank you for listening to this Hackernoon story, read by artificial intelligence. Visit hackernoon.com to read, write, learn and publish.